Previously Asked Questions - Investment Casting Institute

Previously Asked Questions:
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Casting without defects (7/17/)
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Information on the method 7.23 Shell Permeability - Ping-Pong Ball Method (07/02/)
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Are there reuse or recycling options for shell after knockoff? We are currently using a water jet for knockoff.  (5/22/)
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Shell Mold Dryness - Conductivity Method (5/13/)
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​Small (less than 30 gallon) Slurry Mixer(4/4/)
I am on the Advisory Board for the GA Southern Foundry Program.  We are looking for a small slurry mixer that can be used to teach our students the investment process.  The smallest we can find is 30 gallons.  Would anyone know of anything available which is smaller in size?
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Mechanical properties of investment cast A356 vs permanent mold and sand casting (2/10/)
I'm interested in finding out more about the typical mechanical properties of investment cast A356 vs permanent mold and sand casting. Especially for A356-T6.Do you have such data or references to datasheets, such as from AFS?
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Wax Line Temperature Control (2/10/)
We are struggling to maintain uniform line temperature in our wax room going from our conditioning tanks to our presses, this makes shooting waxes at a constant temperature almost impossible.
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Atlas of Wax & Casting Defects - Dataset Request (12/18/)
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Alloy Certifications Specifications  (4/5/)
I am about to purchase some steel investment castings from a foundry, and I was just wondering, what are the typical certification specs that I can request from them?
Such as: adhering to ASTM A732, or ISO____, or porosity limits, or chemical/mechanical test reports, or defect free reports?
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Beryllium Copper Alloy (4/5/)
We have been asked to quote a job in Beryllium Copper and have no experience with it.  From the limited information I've found online, it seems like there are significant challenges associated with casting it.  I am hoping to discuss these challenges with somebody that has experience with it.
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Foundry Dictionary  (03/01/)
I am a student in a French engineer school.  We address many subjects having the need of TOEIC English language proficiency test, however we don't have a professional English class which addressed foundry terms.
So I would like to create a specific dictionary with all regional synonyms, providing a good translation.
Currently, I use "Foundry Dictionary", an application on Playstore.  It is very good and there are many definitions but it is not really complete, nor is it available in print or pdf.
Additionally, I would like to categorize each word for easier search. For example, shrinkage is a defect and sprue is a casting device.
Do you know of such a work? If not, do you know someone who would be willing to help me?
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Non-HAPS Flux for Aluminum Melting (01/14/22)
The Air Quality department of our state is questioning whether the flux used at our foundry contained any hazardous materials.  Who can I speak to about getting a non HAP's flux for aluminum melting?  Typically, we use about 10 cups per year.
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​Slurry Viscosity Measurement (10/20/21)
We are having inconsistency measuring viscosity using the viscosity cup.  Currently, we do the cup test every 2 hours and the plate weight once a shift.  We are considering eliminating the viscosity cup test and do plate weight test every 2 hrs..  Is there a reason one would not want to only measure the plate weight?
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3D Printer (10/06/21)
We need a 3D printer with the capacity to produce models up to 300mm. Please advise.  
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Standards Addressing Porosity in Investment Casting (07/28/21)
We are in the process of trying to locate some governing standards (such as ASME, ASTM, etc.) that address the issue of porosity in investment cast components.  I was wondering if you could point me in the right direction.
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Material Handling - Powders and Sands (06/29/21)
What is the industries preferred way of handling materials when it pertains to; lifting or moving 50# bags of sand and powders?
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Metal Specifications (04/19/21)
I am a metallurgy and materials engineer, I have been working in an investment casting foundry as a production manager for about 2 years. Is there a standard accepted source on ICI metal specifications? and this resource should include chemical analysis and heat treatment and mechanical properties of the material.
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Investment Casting Manganese Material(W.Nr.1.) (Mn12) (03/22/21)
A customer has placed an inquiry for parts cast in manganese alloy (W.Nr.1.).  We are unfamiliar with this alloy and would like to know if it is cast-able using the investment casting process and are there aspects of casting this alloy of which we should be aware. Could the ICI please off some guidance in this area?
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Pouring Temperatures (03/02/21)
I am trying to compile a chart for my boss about the necessary melting and pouring temperatures for specific grades of metals and I was wondering if you would have a good idea of resources to look up this information easily. I have tried looking through the ASTM Standards book as well as looking for resources online with not much to show for it and it would be a great help in building this chart to help our foundrymen. Thank you for your time and input. 
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Aluminum Test Bars (01/13/21)
I hope you can direct me to someone within your institution willing to share some advice on investment aluminum test bars. We have been experimenting here and are getting mixed results.  I have reviewed the technical paper "The Effects On The Mechanical Properties When Using Different Geometry Testbar Coupons."
Per this technical paper, we ran several 1/4" diameter test bars out of 356-T6, with a pour temperature of deg F. and a mold temperature of 995 deg F., but we are experiencing strange results are within the same tree. We had bars pass comfortably and also fail miserably (very low elongation). The entire tree was heat-treated intact before the test bars are removed.
 I did review the ask an expert question, "Improve Mechanical Properties of A357/A356/C355 Aluminum Castings (3/27/19)" We do add Tibor to our melt but not directly in the ladle like your answer suggested.
I have attached a couple of pictures showing our test bar shape and gaiting. We were concerned with the sharp radius of the end of the test bar, so we experimented with a few different shapes with no success.
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Here is the information we will need to quote:
What material do you want part cast out of?

Is the part to be heat treated? If so, is there a hardness requirement? Are there mechanical testing requirements?

Goto Cencho to know more.

What lot quantities of investment castings would you like us to quote? Is this a one time job or a recurring job?
Base on the customer’s demand, if there is no idea, we might request the minimum quantity for each furnace capacity.

We need as much information about the part as possible. This is a new part? If it is an existing job, how is it currently being made? If it is currently being investment cast why are you looking for new foundry? Is to get better quality, delivery or price?

If this is an existing part, does investment casting tooling currently exist for part. If so any tooling rework or modification will be at customer's expense.

We need drawings of 2D and 3D or samples. The more information we receive the fewer questions we will have to ask before we can quote. Ideally we would like to have:

3D CAD files. We would prefer SolidWorks files. If these are not available then this is the desired order.

1. SolidWorks format

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Additional resources:
The Ultimate Buyer's Guide for Purchasing DIN resilient seated gate valve manufacturer

2. STEP format

3. X_T format

4. IGES format

5. STL format

2D drawings. We need these for tolerances. We do make many rapid prototype parts without 2D drawings. But if tolerances are important 2D drawings are a necessity. Note if you only send us a 2D drawing and the dimensions and or tolerances are not legible we will not be able to quote.

Samples if available. This is not a necessity, unless that is all you have, but they can be very helpful during our quoting process

Unless critical dimensions are called out on 2D drawings we will need to know what dimensions are critical and what are not critical.

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